Structured boards with matched surface

ABSTRACT

Surface structured decorative boards ( 1 ) having a first and a second opposite edge ( 1   I  and  1   II  respectively). The board ( 1 ) include an upper side decorative surface ( 2 ) an upper side surface structure and a base layer. The structure is comprised by at least two surface grades ( 10 ) forming a decorative surface pattern on said upper side, said pattern being applied in predetermined fixed positions (P) on the first and the second edges ( 1   I  and  1   II  respectively). The first edge pattern positions (P L ) and the second edge pattern positions (P R ) are matched so that the pattern continues over the first and second edges ( 1   I  and  1   II  respectively) of adjacent boards ( 1 ).

[0001] The present invention relates to decorative boards with matchedsurface structure of the upper surface.

[0002] Products coated with thermosetting laminates are frequent today.They are foremost used where the demand for abrasion resistance is high,but also where resistance towards different chemicals and moisture isrequired. As an example of such products floors, floor beadings, tabletops, work tops and wall panels can be mentioned.

[0003] The thermosetting laminate mostly consists of a number of basesheets with a decor sheet placed closest to the surface. The decor sheetcan be provided with a desired decor or pattern. The most frequentpatterns usually represent the image of different kinds of wood, orminerals such as marble or granite. The surface of the laminate can beprovided with a structure during the laminating procedure which willmake the decor more realistic. Press plates with structure or structurefoils are frequently used when manufacturing such a laminate. A negativereproduction of the structure in the press plate or the foil will beimprinted into the laminate during the laminating procedure.

[0004] The structure suitably represents features characteristic for thepattern the decor represents in the laminate. The structure can be madecoarse to simulate for example roughly planed stone, or smooth withrandomly placed pits and micro cracks to simulate polished marble. Awood surface can for example be simulated by providing the surface withrandomly placed thin oblong indentations which imitate pores. Theseindentations must be oriented in the direction of the growth of thesimulated wood, which is indicated by the pattern of the grains, inorder to make the result realistic.

[0005] It has for a long time been a great need to be able tomanufacture a decorative thermosetting laminate with a decor patternwith a surface structure as life like as the decor reproduced.

[0006] According to the present invention the above mentioned needs havebeen met and a decorative board with a decorative surface with amatching surface structure that overlaps the joints of adjacent boardshas been achieved. The invention relates to surface structureddecorative boards having a first and a second opposite edge. The boardsis also provided with further edges adjacent to said first and thesecond edge. The boards include an upper side decorative surface anupper side surface structure and a base layer. The invention ischaracterised in that the structure is comprised by at least two surfacegrades forming a decorative surface pattern on said upper side. Saidpattern is applied in predetermined fixed positions on the first and thesecond edges. The first edge pattern positions and the second edgepattern positions are matched so that the pattern continues over thefirst and second edges of adjacent boards. This means that the patternclose to the first and second edges are matched so that the boards of aselected range will match giving an impression that the structurepattern continues from one board to another. The pattern of theremaining part of the board is suitably different from one board toanother to create a lifelike impression.

[0007] According to one embodiment of the invention the boards are alsoprovided a third and a fourth edge having a pattern being applied inpredetermined fixed positions on said third and fourth edges. The thirdedge pattern positions and the fourth edge pattern positions are matchedso that the pattern continues over the third and fourth edges ofadjacent boards.

[0008] A surface structured decorative boards according to the presentinvention suitably has a decorative surface which contains a number ofconventional dry base layer paper webs or base layer paper sheets whichare impregnated with a thermosetting resin wherein the resin in theuppermost of these preferably is melamine-formaldehyde resin while therest of the webs or sheets possibly contain melamine-formaldehyde resinor phenol-formaldehyde resin, wherein the decor paper web or decor papersheet respectively, is placed on top of the conventional base layer websor base layer sheets after which the different paper webs or a stack ofsheets respectively are continuously or discontinuously laminatedtogether at an elevated pressure and an elevated temperature. Thesurface layer of the laminate may also include a so called overlaypaper, placed on top of the decor paper. Such an overlay paper ispreferably impregnated with melamine-formaldehyde resin. At least one ofthe thermosetting resin impregnated sheets, preferably the uppermost oneis suitably coated with hard particles, for example silica, aluminiumoxide and/or silicon carbide with an average size of 1-100 μm,preferably around 5-60 μm. The upper side decorative surface is suitablyconstituted of a decorative layer and a ionomeric polymer. Alternativelythe upper side decorative surface is constituted of a decorative layer,a ionomeric polymer and hard particles. According to yet anotheralternative of the invention the upper side decorative surface isconstituted of a decorative layer, a ionomeric polymer, overlay paper,impregnated with melamine formaldehyde and hard particles. Thedecorative layer is suitably made of paper.

[0009] According to one embodiment of the invention the decor patternconsists of a number of sections of parallel rows of bars, where thebars in adjoining rows are mutually offset in the longitudinaldirection. A demarcation consisting of a 1-20 mm wide, preferably 3-10mm wide, field without any surface structure may be used betweenadjacent structure areas. Alternatively, a demarcation consisting of a1-20 mm wide, preferably 3-10 mm wide, field were one surface structuregradually transforms into another surface structure is used.

[0010] Predetermined fixed positions of the structure pattern adjacentthe edges preferably extends over a matching tolerance distance. Thismatching tolerance distance is suitably in the range 1-20 mm, preferablyin the range 1-10 mm and most preferably in the range 1-5 mm.

[0011] The surface grades used for achieving the pattern is selectedfrom the group consisting of; groups of small oblong indentations,different grades of gloss to flat surface finish, ridges and recessesand combinations thereof.

[0012] According to one embodiment of the invention the base layer mayconsist of a number of conventional dry base layer paper webs or baselayer paper sheets which are impregnated with a thermosetting resin. Theresin in the uppermost of these is preferably while the rest of the websor sheets for example may contain melamine-formaldehyde resin orphenol-formaldehyde resin. The decor paper web or decor paper sheetrespectively, is hereby placed on top of the conventional base layerwebs or base layer sheets after which the different paper webs or astack of sheets respectively are continuously or discontinuouslylaminated together at an elevated pressure and an elevated temperature.

[0013] The surface layer of the may suitably include a so called overlaypaper placed on top of the decor paper. The overlay paper is suitablyimpregnated with melanine-formaldehyde resin. At least one of thethermosetting resin impregnated sheets, preferably the uppermost one ispreferably coated with hard particles, for example silica, aluminiumoxide and/or silicon carbide with an average size of 1-100 μm,preferably around 5-60 μm.

[0014] The overlay may alternatively be replaced by, or used togetherwith, a layer of ionomeric polymer where the polymer for example isconstituted of ethylene-methacrylateacid-copolymer while the ions forexample are constituted of sodium, zinc or lithium even though otherionomeric polymers are usable. It is also in this embodiment suitable toutilise hard particles as described above.

[0015] According to one embodiment of the invention the base layerconsists of a particle board or a fibre board. Such a base layer may be5-20 mm thick.

[0016] A board according to the invention may for example be used as afloor board, a wall panel or a ceiling panel. The most popular decorused on floor boards is different kinds of wood as for example oak,birch, beech, ash, cherry, maple, walnut, pine, rosewood, mahogany orebony. Also minerals like marble, granite, sandstone, soapstone andceramic materials are popular reproductions. The surface structures usefor simulating surfaces to mach the above materials may comprise narrowoblong indentations in the surface of 0.1-1 mm width and 0.1-1 mm depthwhich may simulates pores, and cracks of wood. Wood grain may besimulated by sweeping patterns of indentations of 1-25 mm width and0.1-2 mm depth. It is also possible to provide the surface withcombinations of gloss and flat surfaces in sections which additionallymay be raised or recessed.

[0017] The invention is further explained in connection to theaccompanying drawings showing different embodiments of the inventionwhere,

[0018]FIG. 1 shows schematically an embossed surface structureddecorative board 1 in the form of a floor board according to anembodiment of the invention

[0019]FIG. 2 shows schematically end parts of two surface structureddecorative boards 1 according to an embodiment of the invention.

[0020]FIG. 3 shows schematically end parts of two surface structureddecorative boards 1 according to another embodiment of the invention.

[0021]FIG. 4 shows schematically end parts of two surface structureddecorative boards 1 according to yet another embodiment of theinvention.

[0022]FIG. 5 shows schematically end parts of two surface structureddecorative boards 1 according to yet another embodiment of theinvention.

[0023]FIG. 6 shows schematically end parts of two surface structureddecorative boards 1 according the invention. The boards are shown beforecutting.

[0024] Accordingly, FIG. 1 schematically shows parts of a surfacestructured decorative board 1 having a first and a second opposite edge1 ^(I) and 1 ^(II) respectively according to a first embodiment of theinvention. The board 1 includes an upper side decorative surface, anupper side surface structure and a base layer. The structure iscomprised by two surface grades 10 forming a decorative surface patternon said upper side. One of the surface grades 10 is a plane semi-glosssurface while the other surface grade 10 is composed of clusters ofnarrow oblong indentations simulating pores in wood. The pattern isapplied in predetermined fixed positions P on the first and the secondedges 1 ^(I) and 1 ^(II) respectively. The first edge pattern positionsP^(L) and the second edge pattern positions P^(R) are matched so thatthe pattern continues over the first and second edges 1 ^(I) and 1 ^(II)respectively of adjacent boards 1. The boards 1 are most oftenmanufactured in larger formats containing several decorative boards 1which are cut into the desired format and provided with edges. Theseedge are provided with joining functionality like tongue and groove. Thelarge format panels are provided with decor and structure prior to beingcut into user format decorative boards 1. The predetermined fixedpositions P extends over a matching tolerance distance D (see FIG. 6).This matching tolerance distance D is foremost used for ensuring amatching of the structure pattern on the first and second edges ascutting and manufacturing tolerance otherwise could hamper suchmatching. An area C (see FIG. 6) is removed during the cutting andmilling operation when the boards 1 is provided with their end userformat. The matching tolerance distance D is suitably in the range 1-5mm.

[0025]FIG. 2 shows schematically parts of two adjacent surfacestructured decorative board 1 having a first and a second opposite edge1 ^(I) and 1 ^(II) respectively according to a second embodiment of theinvention. The boards 1 include an upper side decorative surface, anupper side surface structure and a base layer. The structure iscomprised by two surface grades 10 forming a decorative surface patternon said upper side. One of the surface grades 10 is a plane semi-glosssurface while the other surface grade 10 is composed of clusters ofnarrow oblong indentations simulating wood pores in sweeping wood grainpattern. The dark sections of the drawing are to be interpreted asindented surfaces. The pattern is applied in predetermined fixedpositions P on the first and the second edges 1 ^(I) and 1 ^(II)respectively. The first edge pattern positions P^(L) (see FIG. 1) andthe second edge pattern positions P^(R) (see FIG. 1) are matched so thatthe pattern continues over the first and second edges 1 ^(I) and 1 ^(II)respectively of adjacent boards 1.

[0026]FIG. 3 shows schematically parts of two adjacent surfacestructured decorative board 1 having a first and a second opposite edge1 ^(I) and 1 ^(II) respectively according to a third embodiment of theinvention. The boards 1 include an upper side decorative surface, anupper side surface structure and a base layer. The structure simulatesthree parallel rows of bars, where the bars in adjoining rows aremutually offset in the longitudinal direction. The structure iscomprised by four surface grades 10 forming a decorative surface patternon said upper side. A first main surface grade 10 is a plane semi-glosssurface while the other surface grades 10 are composed of clusters ofnarrow oblong indentations, narrow indented lines and heavier lines, allsimulating wood grain pattern. The dark sections of the drawing are tobe interpreted as indented surfaces and are also provided with a flatsurface finish to enhance the visual effect. The pattern is applied inpredetermined fixed positions P on the first and the second edges 1 ^(I)and 1 ^(II) respectively. The first edge pattern positions P^(L) (seeFIG. 1) and the second edge pattern positions P^(R) (see FIG. 1) arematched so that the pattern continues over the first and second edges 1^(I) and 1 ^(II) respectively of adjacent boards 1.

[0027]FIG. 4 shows schematically parts of two adjacent surfacestructured decorative board 1 having a first and a second opposite edge1 ^(I) and 1 ^(II) respectively according to a fourth embodiment of theinvention. The boards 1 include an upper side decorative surface, anupper side surface structure and a base layer. The structure iscomprised by three surface grades 10 forming a decorative surfacepattern on said upper side A first main surface grade 10 is a planesemi-gloss surface while the other surface grades 10 are composed ofrandomly arranged narrow oblong indentations and wide indented sweepinglines, all simulating wood grain pattern. The dark sections of thedrawing are to be interpreted as indented surfaces and are also providedwith a flat surface finish to enhance the visual effect. The pattern ofthe wide sweeping lines are applied in predetermined fixed positions Pon the first and the second edges 1 ^(I) and 1 ^(II) respectively (seeFIG. 1). The first edge pattern positions P^(L) (see FIG. 1) and thesecond edge pattern positions P^(R) (see FIG. 1) are matched so that thepattern continues over the first and second edges 1 ^(I) and 1 ^(II)respectively of adjacent boards 1.

[0028]FIG. 5 shows schematically parts of two adjacent surfacestructured decorative board 1 having a first and a second opposite edge1 ^(I) and 1 ^(II) respectively according to a fifth embodiment of theinvention. The boards 1 include an upper side decorative surface, anupper side surface structure and a base layer. The structure iscomprised by three surface grades 10 forming a decorative surfacepattern on said upper side. A first main surface grade 10 is a planesemi-gloss surface while the other surface grades 10 are composed ofrandomly arranged narrow oblong indentations and narrow indentedsweeping lines, all simulating wood grain pattern. The dark sections ofthe drawing are to be interpreted as indented surfaces. The pattern ofthe wide sweeping lines are applied in predetermined fixed positions Pon the first and the second edges 1 ^(I) and 1 ^(II) respectively (seeFIG. 1). The first edge pattern positions P^(L) (see FIG. 1) and thesecond edge pattern positions P^(R) (see FIG. 1) are matched so that thepattern continues over the first and second edges 1 ^(I) and 1 ^(II)respectively of adjacent boards 1.

[0029]FIG. 6 is to be studied together with FIG. 1.

[0030]FIG. 7 shows schematically parts of several adjacent surfacestructured decorative board 1 having a first and a second opposite edge1 ^(I) and 1 ^(II) respectively as well as third and fourth oppositeedges 1 ^(III) and 1 ^(IV) respectively according to a specialembodiment of the invention. The boards 1 include an upper sidedecorative surface, an upper side surface structure and a base layer.The structure is comprised by two surface grades 10 forming a decorativesurface pattern on said upper side. A first main surface grade 10 is arough flat surface while the other surface grade 10 is a gloss surface.The dark sections of the drawing are to be interpreted as indentedsurfaces. The pattern is applied in predetermined fixed positions P (seeFIG. 1) on the first, second third and fourth edges 1 ^(I), 1 ^(II), 1^(III), and 1 ^(IV) respectively. The first edge pattern positions P^(L)(see also FIG. 1) and the second edge pattern positions P^(R) (see alsoFIG. 1) as well as the third edge pattern positions P^(U) and the fourthedge pattern positions P^(D) are matched so that the pattern continuesover the first, second, third and fourth edges 1 ^(I), 1 ^(II), 1 ^(III)and 1 ^(IV) respectively of adjacent boards 1.

[0031]FIG. 8 shows schematically a surface structured decorative board 1having a first and a second opposite edge 1 ^(I) and 1 ^(II)respectively according to a second special embodiment of the invention.The boards 1 include an upper side decorative surface, an upper sidesurface structure and a base layer. The structure is comprised by twomain surface grades 10 forming a decorative surface pattern on saidupper side. A first main surface grade 10 is a plane semi-gloss surfacewhile the other main surface grade 10 is composed of randomly arrangednarrow oblong indentations arranged in sweeping lines simulating woodgrain pattern. The dark sections of the drawing are to be interpreted asindented surfaces and are also provided with a flat surface finish toenhance the visual effect. The pattern of the wide sweeping lines areapplied in predetermined fixed positions P on the first and the secondedges 1 ^(I) and 1 ^(II) respectively (see FIG. 1). The first edgepattern positions P^(L) (see FIG. 1) and the second edge patternpositions P^(R) (see FIG. 1) are matched so that the pattern continuesover the first and second edges 1 ^(I) and 1 ^(II) respectively ofadjacent boards 1. The third and fourth edges 1 ^(III) and 1 ^(IV)respectively are provided with a longitudinal indented line intended tosimulate a seam. The line has a flat surface finish.

[0032] The invention is not limited by the shown embodiments since theycan be varied in different ways within the scoop of the invention. It isfor example the intended that the structure pattern according to theinvention is to be used together with decorative sheets which simulatesfor example different kinds of wood. It is also possible to simulate thestructure of other materials and match them in a way as described above.Such pattern may be fabric, minerals like polished marble or evencompletely fantasy based patterns.

1. Surface structured decorative boards (1) having a first and a secondopposite edge (1 ^(I) and 1 ^(II) respectively), which board (1) includean upper side decorative surface an upper side surface structure and abase layer, wherein the structure is comprised by at least two surfacegrades (10) forming a decorative surface pattern on said upper side,said pattern being applied in predetermined fixed positions (P) on atleast the first and the second edges (1 ^(I) and 1 ^(II) respectively),that the first edge pattern positions (P^(L)) and the second edgepattern positions (P^(R)) are matched so that the pattern continues overthe first and second edges (1 ^(I) and 1 ^(II) respectively) of adjacentboards (1).
 2. Surface structured decorative boards (1) according toclaim 1 the boards further having a third and a fourth edge (1 ^(III)and 1 ^(IV) respectively), wherein said pattern being applied inpredetermined fixed positions (P) on the third and the fourth edges (1^(III) and 1 ^(IV) respectively), that the third edge pattern positions(P^(U)) and the fourth edge pattern positions (P^(D)) are matched sothat the pattern continues over the third and fourth edges (1 ^(III) and1 ^(IV) respectively) of adjacent boards (1).
 3. Surface structureddecorative boards (1) according to claim 1 wherein the decorativesurface contains a number of conventional dry base layer paper webs orbase layer paper sheets which are impregnated with a thermosetting resinwherein the resin in the uppermost of these preferably ismelamine-formaldehyde resin while the rest of the webs or sheetspossibly contain melamine-formaldehyde resin or phenol-formaldehyderesin, wherein the decor paper web or decor paper sheet respectively, isplaced on top of the conventional base layer webs or base layer sheetsafter which the different paper webs or a stack of sheets respectivelyare continuously or discontinuously laminated together at an elevatedpressure and an elevated temperature.
 4. Surface structured decorativeboards (1) according to claim 1 wherein the base layer consists of aparticle board or a fibre board.
 5. Surface structured decorative boards(1) according to claim 1 wherein the decor pattern consists of a numberof sections of parallel rows of bars, where the bars in adjoining rowsare mutually offset in the longitudinal direction.
 6. Surface structureddecorative boards (1) according to claim 5 wherein a demarcationconsisting of a 1-20 mm wide, preferably 3-10 mm wide, field without anysurface structure is used between adjacent structure areas.
 7. Surfacestructured decorative boards (1) according to claim 5 wherein ademarcation consisting of a 1-20 mm wide, preferably 3-10 mm wide, fieldwere one surface structure gradually transforms into another surfacestructure
 8. Surface structured decorative boards (1) according to anyof the claims 1-7 wherein the surface layer of the laminate includes aso called overlay paper, placed on top of the decor paper.
 9. Surfacestructured decorative boards (1) according to claim 8 wherein theoverlay paper is impregnated with melamine-formaldehyde resin. 10.Surface structured decorative boards (1) according to claim 3 or 8wherein at least one of the thermosetting resin impregnated sheets,preferably the uppermost one is coated with hard particles, for examplesilica, aluminium oxide and/or silicon carbide with an average size of1-100 μm, preferably around 5-60 μm.
 11. Surface structured decorativeboards (1) according to claim 1 wherein the upper side decorativesurface is constituted of a decorative layer and a ionomeric polymer.12. Surface structured decorative boards (1) according to claim 1wherein the upper side decorative surface is constituted of a decorativelayer, a ionomeric polymer and hard particles.
 13. Surface structureddecorative boards (1) according to claim 1 wherein the upper sidedecorative surface is constituted of a decorative layer, a ionomericpolymer, overlay paper, impregnated with melamine formaldehyde and hardparticles.
 14. Surface structured decorative boards (1) according to anyof the claims 10-13 wherein the decorative layer is made of paper. 15.Surface structured decorative boards (1) according to claim 1 whereinpredetermined fixed positions (P) extends over a matching tolerancedistance (D).
 16. Surface structured decorative boards (1) according toclaim 15 wherein the matching tolerance distance (D) is in the range1-20 mm.
 17. Surface structured decorative boards (1) according to claim15 wherein the matching tolerance distance (D) is in the range 1-10 mm.18. Surface structured decorative boards (1) according to claim 15wherein the matching tolerance distance (D) is in the range 1-5 mm. 19.Surface structured decorative boards (1) according to claim 1 whereinthe surface grades (10) is selected from the group consisting of; groupsof small oblong indentations, different grades of gloss to flat surfacefinish, ridges and recesses and combinations thereof.